1、PCB China Application Engineer : 徐能伟 Cell phone: 18611751496 E-mail: ,汽车疲劳耐久性试验数据采集与应用,1,2,PCB集团简介整车和零部件性能试验汽车疲劳耐久试验载荷分解与疲劳分析PCB车轮六分力传感器,Agenda,3,PCB GROUP,Established 1967 成立于1967年 Located on 6 acres near Buffalo, New York, USA 位于美国纽约布法罗市 Specialise in sensors for rapid and steady-state pressure, f
2、orce, acoustic and vibration measurements 致力于快速和稳态压力、力、声学和振动测量 Represented in over 50 countries 在超过50个国家设有代表处或分销商 AS9100 Certified, ISO 9001 Certified, A2LA Accredited to ISO 17025 AS9100认证，ISO9001认证，A2LA认证,4,PCB GROUP,Vibration, Shock, Pressure, Force, Load, Torque, Acoustic Measurement Solutions 振
3、动、冲击、压力、力、载荷、扭矩、声学等测试解决方案,Signal Conditioner 信号调理器,WFT 六分力传感器,DC Accelerometer DC 加速度计,3-Component Dynamic Force 三分量动态力传感器,Pressure Transducer 静/动态压力传感器,Miniature Accelerometer 小型加速度计,TORKDISK 扭矩传感器,Load Cell 载荷称重传感器,Human Vibration Meters 人体振动表,High Sensitivity Microphones 高灵敏度传声器,Sound Level Meter
4、s 声级计,5,Calibration 传感器标定系统,Shakers 激振器,Instrumented Steering Wheel 测力方向盘,PCB GROUP,,Headquarters in Buffalo New York,6,北 京,上海,深圳,PCB China,整车与零部件性能试验规范制定流程,顾客需求,市场规范,整车性能规范,产品定义,整车性能与子系统的关系,子系统性能规范,整车性能规范向子系统分解,子系统性能规范向零部件分解,零部件性能规范,整车与零部件性能试验,7,整车与零部件试验,整车道路试验 整车不同路面试验噪音与振动测试 实验室试验 整车转鼓试验台试验 整车模态试
5、验 零部件模态试验 进气噪音测试 排气噪音测试 转递函数测试 整车漏声测试 减震降噪材料试验 吸音系数测试 声音传递损失测试 阻尼特性测试 橡胶件刚度测试,振动与噪声试验,整车道路载荷测试整车疲劳试验零部件载荷测试零部件疲劳试验整车应力测试零部件应力测试,疲劳与强度试验,整车与零部件性能试验,8,汽车疲劳耐久解决方案流程,汽车疲劳耐久试验,9,测试步骤,1. 对所有的通道和传感器进行命名和编号。,10,测试步骤,2. 确认方向,1）加速度计方向与整车坐标系的关系 2）位移传感器：拉伸为正，压缩为负 3）方向盘转角：左转为正,3. 对分段采集的工况名称，采集次数要预先编号，让其与实验工况的名称一
6、致，如制动工况、蛇形工况等等。,4. 采集之前，测量各轮胎气压以保证气压一致，同时测量各轮胎静态载荷；记录天气和室外温度，风速和方向，路面是否积水等； 轮胎一定要做动平衡。,6. 在采集完之后，让汽车处于水平路面，发动机怠速，记录数据10秒钟；,5. 在正式上路采集之前，让汽车处于水平路面，发动机怠速，记录数据10秒钟 ；,11,测试步骤,8. 采集完一种工况，看看数据质量，如好再继续；否则要查明原因再继续；,7. 先测空载，然后满载；先测好路面，然后坏路面；每种工况测三次；,9. 确保所有数据通道点数和采样频率一致,12,测试步骤,10. 确保制动信号的采集连续，真实反映驾驶员刹车过程，即从
7、驾驶员的脚踏上并压下制动踏板然后放开，整个过程的信号都将是-5伏，其它时候都将是0。因此在采集完成后，要对此进行处理；,13,测试步骤,11. 有条件的话，可以采用给特征路面标记,14,测试步骤,12. 采集完成后，要对所有加速度信号进行低通滤波器滤波，并注意没有相位移动；最后对所有采集的信号要进行检查，在确保信号没问题后，再拆解测试仪器。13. 完成测试报告，并对所有测试通道的正负极和测量信号名称与内容给予明确说明，必要时附以照片帮助说明（要特别注意的是，车辆参考坐标系的XYZ方向，按右手螺旋法则，X：水平指向车后；Y：水平指向车右；Z：垂直指向车上。因此对各通道正负极说明时，尽可能用车辆参
8、考坐标系说明）。,15,记录试验车状态,16,设备仪器安装调试,每一个设备仪器都需要调试正常，应变最好有补偿，做成半桥或者全桥。数据线一定采用高屏蔽的线缆。,通道很多，一个数采可能不够，可以用多个，最好所有通道一次同步采集，必 要时用路由器同步。,供电：电源最好采用直流电瓶。六分力传感器单独供电，电瓶必须固定。,加速度计等传感器必须固定在大的不易变形的零件上，固定支架必须保证最够的强度和刚度。,17,车轮六分力传感器,测力方向盘,设备仪器安装调试,18,三向加速度传感器,GPS天线,应变片,拉线式位移,设备仪器安装调试,19,制定严格全面的道路试验规范。,试验规范,20,试验规范,21,原则：
9、测试过程中，确保试验数据的可靠与准确性。（为了确保数据质量，在正式测试之前，进行一个试测。试测的工况可以选择加速+制动+转向的工况，然后进行数据检查和校队。）,测试原则,六分力传感器输出信号,22,左右悬架位移信号,左前轮轴头三向加速度信号,23,左前轮轴头三向加速度信号,24,汽车在行驶过程中，不平路面的激励以及驾驶员输入（转向，加速，制动）将导致汽车行驶状态的变化。这种变化将使车轮载荷随时间而变，进而悬架各零部件之间发生相对位移。这种相对位移的产生源于悬架各零部件之间的动态载荷所发生的相对变化，故而在行驶里程累计到一定程度后，某些零部件将会疲劳破坏。因此有效的获取悬架零部件动态载荷时间历程
10、，是分析和设计零部件耐久性能的重要工作。一般来说，悬架结构强度和疲劳分析可以分为零部件级和系统级分析方法。零部件级分析：采用多体动力学方法得到悬架硬点载荷，对单一结构进行分析的方法；系统级分析方法：以整个悬架为基础，同时考虑衬套、限位块刚度以及零部件间相互运动的影响的分析方法。零部件级分析方法原理简单，而且容易将分析过程流程化、规范化，从而保证分析结果的准确性和一致性；系统级分析方法，由于能够考虑几乎所有的悬架本身特性，如非线性连接关系、运动关系等特性，因而可以得到更为准确的分析结果。,载荷分解,25,疲劳分析,26,疲劳分析五框图,疲劳分析,27,转向节单位载荷作用下应力场,疲劳分析,制动工
11、况,砾石路工况,卵石路工况,转向节疲劳寿命结果,28,PCB Load and Torque Acquired Key Transducers in 19991999年并购Key Transducers公司Acquired RS Technologies assets in 2009于2009年收购RS Technologies公司 Engineers and manufactures load cells, torque transducers, wheel force transducers 设计和制造载荷传感器、扭矩传感器以及六分力传感器 Engineers and manufactur
12、es tooling systems based on load and torque applications (torque angle transducers, torque wrenches, acquisitions units)基于载荷和扭矩的应用，设计和制造相应的延伸产品（扭矩角度传感器，扭矩扳手，采集模块） Markets to automotive, aerospace and rail applications应用领域涉及汽车，航空航天以及铁路,PCB Wheel Force Transducer PCB 车轮六分力传感器,29,History of Wheel Force
13、 Transducer 车轮六分力传感器发展历史,Invented in 1972 Ralph Shoberg, RS Technologies Owner由RS原拥有人Ralph Shoberg发明于1972年 Ford Motor Company Crown Victoria (note low profile design)与福特公司联合设计（扁平型设计）, 用于维多利亚皇冠型轿车,30,History of Wheel Force Transducer 车轮六分力传感器发展历史,Single Piece Design 整体式设计L Strut Configuration L型桥路设计C
14、abling through Spindle 信号由特殊改制的传动轴输出,31,History of Wheel Force Transducer 车轮六分力传感器发展历史,Original complete one wheel system with Transducer Interface Unit (TIU) 最初的一套完整的六分力传感器系统，带TIU接口单元,32,History of Wheel Force Transducer 车轮六分力传感器发展历史,AT Caldwell Award for Technical Paper on WFTWFT技术论文所获奖励,33,Histor
15、y of Wheel Force Transducer 车轮六分力传感器发展历史,Second Generation Evolves to be like the modern WFT第二代-与现在主流的WFT产品已经非常相似,34,Series 5400 Wheel Force Transducer 5400系列车轮六分力传感器,essentially a “disk” designed to replace the center of the vehicle rim that is strain gaged to measure forces and moments about its c
16、enter 本质上来说，它就是一个替代汽车轮辋中心部分的圆盘，通过其上的应变片来测量作用在车轮中心位置上的力和扭矩。,So what exactly is a Wheel Force Transducer? 什么是车轮六分力传感器？,35,a 6 degree of freedom sensor capable of measuring vertical, lateral, and longitudinal forces simultaneously with brake, steer, and camber moments 在车轮制动、转向和外倾时，能够同时测量车轮的垂直、侧向及纵向的力和扭
17、矩的六自由度的传感器。,Series 5400 Wheel Force Transducer 5400系列车轮六分力传感器,What does it do? 它用来做什么？,36,ideally that sensor would allow for accurate translation of the rotating measurements into the more useful inputs to the vehicle at the tire patch or the spindle such as vertical, lateral, and longitudinal forc
18、es simultaneous with brake, steer, and camber moments 理想状态下，传感器能够测量车轮制动、转向和外倾时的垂直、侧向及纵向的力，并对这些测量的参数进行精确转换，从而得到更有用的通过车轴或者车轮传递给汽车的输入量。,Series 5400 Wheel Force Transducer 5400系列车轮六分力传感器,37,Mx,Mz,Fz,Fx,Fy,My,Not only did PCB make the first Wheel Force Transducer, we also made the first single piece desi
19、gn PCB不仅仅是第一套WFT的设计制造者，同时也是单片式设计的发明者,Series 5400 Wheel Force Transducer 5400系列车轮六分力传感器,38,like all WFTs, the strain gaged elements rotate as the wheel rotates, rendering the in-plane forces and moments “unresolved” and rotating, too 和所有的WFT一样，当车轮旋转的时候，应变片也会旋转，面内的力和扭矩也一起旋转to provide more useful measu
20、rements to engineers, the coordinates of these unresolved forces and moments are transformed to vehicle coordinates, often at the tire patch center or spindle center. 为了给工程师提供更有用的测量数据，这些旋转坐标系的力和扭矩要转换为车辆坐标系。,Fy,My,Series 5400 Wheel Force Transducer 5400系列车轮六分力传感器,39,“O” = Offset or distance from the
21、wheel center-line to the wheel-to-spindle mating surface 车轮中心线与车轮轴配合面的间距,Standard “Single” tire/wheel cross-section 标准单轮截面图,Series 5400 Wheel Force Transducer 5400系列车轮六分力传感器,40,Single wheel WFT set-up 单轮WFT结构,The wheel force transducer is designed to replace the center hub of a specially machined ri
22、m or wheel and strain gaged to measure 3 forces and 3 moments simultaneously about its center. 车轮六分力传感器安装在经过特殊加工的轮辋和轮毂之间，并利用应变片来同时测量中心位置上的3个方向的力及3个方向的扭矩。,Series 5400 Wheel Force Transducer 5400系列车轮六分力传感器,41,Wheel offset from the centerline of the tire to the centerline of the transducer produces a m
23、oment about the vehicle X-axis due to the vertical load. When considering the load rating of the transducer, this moment is added to the moment produced by side loading at the tire patch. On-line correction for this offset is available 由于垂直载荷使得车轮中心线与传感器中心线之间产生一个沿车辆X轴方向的扭矩。如果考虑传感器的额定载荷，这个扭矩就被加载到了车轮侧面
24、负载所产生的扭矩之上，对于这个偏置可以进行在线修正。,Single wheel WFT set-up 单轮WFT结构,Series 5400 Wheel Force Transducer 5400系列车轮六分力传感器,42,Dual wheel WFT set-up 双轮WFT结构,PCB is the only company to offer a flexible enough WFT design that the sensor may be “reused” in various wheel configurations and axle locations. The PCB WFT
25、may be used for driven and trailing axles, front turning or tag axles, and single, super single, and dual wheel set-ups. PCB是唯一一家能够提供灵活的WFT设计方案的公司，传感器可以在各种车轮配置及车轴位置情况下重复使用。PCB的WFT可以用于驱动牵引轴，前转向或连接的轴，单轮，超大单轮或者双轮结构。,Series 5400 Wheel Force Transducer 5400系列车轮六分力传感器,43,Super Single wheel WFT set-up 超大单轮
26、WFT结构,This configuration is quite common with heavy truck vehicles in Europe. 该结构在欧洲的重卡车型中极为普遍,Series 5400 Wheel Force Transducer 5400系列车轮六分力传感器,44,5400系列车轮六分力传感器主要由传感器、放大器、滑环、信号调理仪、电缆等组成。,信号调理仪,电缆,Series 5400 Wheel Force Transducer 5400系列车轮六分力传感器,45,Cross Sectional View of WFT WFT横截面图,Sensor 传感器,Sl
27、ip Ring Adapter 滑环适配器,Hub Adapter 轮毂适配器,Custom Rim 定制轮辋,Slip Ring Assembly* 滑环套件,Vehicle Hub 车辆轮毂,tire walls 轮胎壁,*Telemetry available 遥测可选,Series 5400 Wheel Force Transducer 5400系列车轮六分力传感器,46,Class 10.9 or better lug bolt fasteners with a unique tapered face for increased clamp load of Sensor to whe
28、el and hub, signal cable, tether rod and suction-cup clamps to provide a fixed mechanical “zero” reference for coordinate transformations 10.9级或者更好的扁尾螺栓紧固件，独一无二的锥形面设计，可以增加传感器与车轮和轮毂之间的夹紧力，信号线，线头和吸入式锥形夹头可以提供固定的机械零点参考-用于坐标系转换,Required Accessory Package 附件包,Specific to every application based upon tire
29、size, axle type, and bolt pattern - PCB recommends (and will design and deliver) rims for wheel force transducer - machined from forged Alcoa 6061-T6 AL not welded 基于各种应用的轮胎尺寸，车轴类型以及螺栓式样定制-PCB推荐(并负责设计和运输)适用于WFT的定制轮辋，由6061-T6 AL式铝材锻造，非焊接成型,Custom Rim 定制轮辋,Single machined adapter bolts between sensor
30、and vehicle hub interface - available for passenger car and light truck. Heavy truck/bus sensors have integral hub or universal hub adapter (to allow same sensor to be used on US, EU or Military wheels 位于传感器和车辆轮毂之间的整体式螺栓接口适配器，适用于乘用车和轻卡，重卡和客车具有集成的轮毂以及通用的轮毂适配器(使美式、欧式以及军用车轮均可以使用同样的传感器),Hub Adapter 轮毂适配
31、器,slip ring, encoder - instrument quality encoders capable of transferring amplified signals of sensors Forces, Moments, angular position, and speed滑环，整合了编码器，能够将放大后的传感器的力和扭矩，角位置及车速等信号进行传输,Slip Ring Assembly 滑环套件,Single machined interface to outboard of WFT sensor - provides protected passage of unam
32、plified connections of sensor to preamplifier ring on outer edge of wheel - sized to selected sensor and rim WFT传感器外侧的整体式接口，能够为传感器和车轮外侧的前置放大器之间的未放大信号提供保护，并提供与传感器和轮辋的尺寸匹配,Slip-Ring Adapter 滑环适配器,Single machined piece of metal (aluminum, stainless steel, or titanium) - designed with 6 individual strai
33、n gage bridges each sensitive to one of 3 forces or 3 moments 整体式金属加工(铝、不锈钢、钛)，由六组独立的应变式电桥组成，分别感应三个方向的力和扭矩,WFT Sensor 车轮六分力传感器,DESCRIPTION,PART NAME,TIU,Transducer Interface Unit (TIU) 传感器信号调理仪,Amplifies signals and transforms rotating signals of sensor to vehicle coordinates - outputs resolved forc
34、e, moment, speed and position signals 对信号进行放大，并将传感器的旋转信号变换到车辆坐标系- 输出转换之后的力、扭矩、车速以及位置信号,Series 5400 Wheel Force Transducer 5400系列车轮六分力传感器,47,WFT 技术规格,Series 5400 Wheel Force Transducer 5400系列车轮六分力传感器,48,5410 - 5413 Example,Slip Ring Assembly,Sensor,Slip Ring Adapter,Hub,Hub Adapter,Custom Wheel,Serie
35、s 5400 Wheel Force Transducer 5400系列车轮六分力传感器,49,5414 and 5415 Examples,Dual Rear,Single,Ex: slip ring with amplifier,Sensor,Carrier (top hat),Hub,Series 5400 Wheel Force Transducer 5400系列车轮六分力传感器,50,Competitive Edge 竞争优势,Proven 1-piece sensor (increased efficiency, unparalleled value): 整体式传感器 (提高效率)
36、Fast set-up and calibration 快速设置和校准Widest flexibility 灵活性强Unique safety and reliability features 独一无二的安全性和可靠性Durability 耐久性,51,Fast set-up and calibration 快速设置和校准 No hub adapter required for heavy truck mounts right onto test vehicle 重卡不需要轮毂适配器-正确安装于测试车辆即可 Superior temperature performance (Tmax 150C
37、, compensation 0.005%/ ) ideal for brake studies 优越的温度稳定性(温度上限150C，补偿0.005%/)-制动研究的理想选择,Competitive Edge 竞争优势,Fast Setup and Calibration 快速设置和校准,52,Competitive Edge 竞争优势,Widest Flexibility 灵活性强,Signal transmission includes slip ring or telemetry 信号传输可通过滑环或者遥测两种方式 Accommodates steered, dual rear, sup
38、er single, or trailing wheels/axles 适用于操控、双轮、超大单轮或者单轮的车轮 No recalibration required when switching wheel configurations 改变车轮设置的情况下无需再校准 Universal heavy truck hub adapter available 通用的重卡轮毂适配器 easily switch from US - Euro Military 美式、欧式和军用车辆任意变换,53,Exclusive fastening technology - higher clamp load, gr
39、eater security 独有的紧固技术，夹紧力更大，更安全 Highest water/dust ingress protection 最高的防水防尘保护 Temperature compensation integrated into the transducer传感器集成温度补偿Minimal crosstalk due to unique design for struts 独立式设计使得交叉干扰最小,Competitive Edge 竞争优势,Unique safety and reliability features 独一无二的安全性和可靠性,54,Lightest WFT s
40、ensor and assembly 最轻的安装好的轮力传感器 Durable design (available in AL, SS, or Ti) 耐久设计(铝、不锈钢、钛可选) 150% FS overload rating simultaneous in all axes 150% FS 各轴向同时的过载保护 Integral stops for extreme overload protection 过载保护立刻停止工作，保护传感器,Competitive Edge 竞争优势,Durability 耐久性,55,Applications 应用,One transducer for s
41、everal applications: 一种传感器，多种应用： Road load data acquisition (RLDA)道路载荷试验数据采集 Road Simulation Testing on a variety of manufacturers testing systems基于制造商的各种测试设备的道路模拟试验 Tire characterization and tread wear testing 轮胎性能和胎面磨损试验 Suspension characteristics analysis 悬架特性分析 Vehicle Dynamics Model development
42、车辆动力学模型开发 NVH and Ride & Handling振动噪声舒适度、乘坐和操控性分析,56,Perform data acquisition on a variety of vehicles with the same sensor 用同样的传感器在各种车辆上进行试验数据采集 Minimal set up time 最短的设置时间 Reliable data out to 400 Hz 达400Hz的可靠数据,Applications 应用,Road load data acquisition (RLDA) 道路载荷试验数据采集,57,Use the transducer wit
43、h either custom or OEM testing systems 可在定制的或者OEM的测试系统中使用传感器 Analog signals feed right into the servo or dynamometer controller 模拟信号传输给伺服控制器或者测功机 Communicates to any test system 能与任何测试系统通讯,Applications 应用,Road Simulation Testing 道路模拟试验,58,Applications 应用,Tire characterization and wear 轮胎性能和磨损试验,Perf
44、orm multi degree of freedom characterization for tires 检测轮胎多自由度的特性 Static or dynamic characterization 静态或动态特性,59,Applications 应用,Suspension characteristics analysis 悬架特性分析,DECOUPLED CONCEPT, MOVING VEHICLE 解耦合，使车辆运动 Full-vehicle durability test rig for service load simulation 台架道路模拟的整车耐久试验,COUPLED H
45、EXAPOD CONCEPT, FIXED AXIS 六脚耦合，固定轴向 One corner of a suspension test rig with suspension 悬架一脚的台架试验,60,Applications 应用,Vehicle Dynamics Model Development 汽车动力学模型开发,Correlate the engineering models to the actual data for a more precise design 将工程模型与实际的数据关联起来，以便于更加精确的设计,61,Applications 应用,Ride and Hand
46、ling & NVH 乘坐和操控性、振动噪声舒适度,Perform NVH studies on vehicles in the test lab as well as collect ride and handling data on a proving ground or test track 在实验室测试车辆的NVH性能，同时也在试验场或者试车跑道上采集乘坐和操控性数据,62,Examples of WFTs 轮力传感器实例,63,Examples of WFTs 轮力传感器实例,64,Examples of WFTs 轮力传感器实例,65,66,Examples of WFTs 轮力传
47、感器实例,PCB WFT Customers PCB WFT 客户,PCB Series 5400 customers are performance driven: PCB 5400系列产品用户： Ford Motor Company (USA) BMW (Germany) Daimler Benz (Germany) FAW (China) Nissan (Japan) Visteon (USA) MCI Coach (USA) ArvinMeritor (USA) Volvo Truck (Sweden & USA) Ssang Yong (Korea) Axle Alliance (U
48、SA) Citroen Racing (France) More,67,Instrumented Steering Wheel 测力方向盘,Instrumented Steering Wheel System (5600 Series) 5600系列测力方向盘 Passenger Car and Truck models available 可用于客车和卡车 IR telemetry provides friction-free wireless transmission IR遥测提供无摩擦无线传输 Inertial moment and weight comparable to OEM st
49、eering wheels 惯性扭拒和重量优于OEM方向盘 Two ranges of each measurement available at all times(steering moment, angle, and angle velocity) （转动扭拒、角度和角速度） Fast, easy, and backlash-free mounting 快速、容易、正确安装 Highly accurate and reliable 高精度和可靠性 Integrated wireless power supply 集成无线电源 Small, compact display system 简单紧凑的显示系统,68,69,Thank You!,
